Recommended Installation Procedures and Instructions:
CYLINDER HEAD TORQUE
- Properly torque cylinder head at installation to OE specifications in the correct sequence. (Use new bolts when OE required).
INTAKE MANIFOLD MUST BE CLEANED
- Clean off carbon (remove steel heat shield, if equipped, clean and re-install.)
- Magnetic particle inspect or die check for cracks.
- Blow out with compressed air to avoid having foreign material enter combustion chamber.
- Remove baffle (where applicable) so that all collected contaminants can be removed.
- All EGR passages must be cleaned and free of obstruction.
- Do not over torque manifold bolts. Use OE torque specifications and sequence ONLY.
- Do not glass bead intake manifolds to clean.
- Check water outlet for corrosion.
- Consult shop service manual for dry lash setting for non-adjustable rocker arms.
- Check dry lash at time of installation (if applicable).
- Check and adjust lash at 500 miles (if applicable).
ROCKER ARM ASSEMBLIES
- Check for wear and replace if necessary (remanufactured units are available).
- Confirm proper shaft installation - as it is possible to install the assembly upside down. Excessive oil consumption may result.
- Check bushing, mechanical advance, vacuum advance, and total advance.
- Check to see that distributor is fully engaged and locked in the oil pump at proper depth.
- Adjust ignition timing to factory specifications.
- Check distributor drive gear for wear and replace as needed.
- Carefully service or replace all aspects of the fuel system, i.e. pump, lines, carburetor or fuel injection components.
- Check fuel lines for breaks and crimps.
- Use only approved steel lines.
- Check fuel pump for proper pressure
- Check double diaphragm type for faulty vacuum booster which may pump oil through the intake system.
- Replace all filters at time of installation and at O.E. recommended intervals. These filters include air, oil, fuel, and crankcase.
- Clean air cleaner housing; crankcase vent tubes, coolers, air compressors, Donaldson valves, etc.
- Recore or replace the radiator and test flow.
- Verify thermal conductivity. Minimum of 25°F degrees temperature differential between inlet and outlet.
- Always replace pressure cap and thermostat.
- Check temperature sending unit fan switch.
HEAT RISER OR EXHAUST THERMOSTAT CONTROL
- Check to see if unit is free and operating properly..
- Lubricate with special high heat formula.
- Make sure hot air door operates freely on air cleaner.
- Fill to proper level.
- Use only OE specified lubricants or equivalent to full levels before operation.
- Use a pressure tank at about 40 pounds pressure to prime (pre-lube) engine as this will insure vital parts are lubricated properly to avoid a dry start. (Spinning of the oil pump to accomplish this is not recommended).
- If pressure tank is unavailable, use an aftermarket assembly lubricator kit for prelubing of system before initial start up (follow recommended procedures). Call for further information.
- Install new oil pump and pickup screen.
- Install new oil filter filled with new oil prior to installation.
- Check oil pump intermediate shaft for correct size and shape to match distributor and oil pump, if applicable.
- Oil pump may need to be primed before starting (Run at 800 RPM at intervals before releasing to customer for use to assure proper cylinder lubrication).
- Replace oil pressure sending unit.
- Clean or replace oil cooler (if applicable)
- Adjust clutch to proper free pedal BEFORE starting engine, NOT after.
- Check crankshaft end thrust before and after transmission to engine.
- PLEASE NOTE!!!-excessive main bearing thrust wear may be caused by the following:
- Clutch not adjusted properly
- Interference between pilot shaft and crankshaft
- Interference between torque converter and crankshaft
- Torque converter ballooning
- Blockage and/or restriction of transmission oil cooler
- Bent, kinked or damaged supply lines
- Incorrect crankshaft end thrust
PREVENTING THE CAUSES OF THRUST BEARING FAILURE IS THE RESPONSIBILITY OF THE INSTALLING TECHNICIAN!!
- Don't overlook small parts such as belts, hoses (those that carry liquids and air) and motor mounts which become weak and worn with age. We suggest that these items be replaced at time of engine replacement.
- Be sure to service and inspect accessories such as alternator, starter, water pump, air compressor, fuel system, EGR valves and all sensors to avoid premature engine failure.
- On engines that use a 1-piece full circle rear main seal and flangeless flywheel mounting system, over torque of the flywheel bolts may distort the rear seal area and cause an oil leak.
- Check oil pressure.
- Engine should start. Avoid excessive cranking.
- Check for oil and water leaks.
- Install radiator cap after coolant is observed to be circulating (some thermostats may air lock and prevent proper circulation of coolant).
MODULATOR VALVE (Located on automatic transmission)
- Pull off lines; if valve is defective, oil may be present.
- Replace if above condition is observed, as it may allow transmission fluid to enter engine through vacuum system and prevent proper ring seal.
EXHAUST MANIFOLD PRESSURE & SYSTEM
- Replace oxygen sensor with a low pressure gauge.
- Run engine at 2500 RPM for 1 minute.
- High-pressure reading should be less than 2.5 pounds.
- A pressure reading over 2.5 pounds indicates an exhaust system restrictions, which will cause engine damage. Check catalytic converters and exhaust systems for restrictions.
- Inspect exhaust manifold for internal and external cracks, especially on marine applications.
- Make an engine analysis data sheet (either a diagnostic printout or handwritten form) showing the status of the engine and the Engine Support System before installation, after installation and at the 500-mile checkup.
- Check following items for possible problems:
- Check engine or service engine soon lights (computer-control problems).
- Check for any trouble codes, this may be a clue to why the engine previously failed.
- Check for correct vacuum hose routing and for vacuum leaks.
- On computerized emission control systems, check the following items that are applicable:
Throttle position sensor (TIS)
Mixture control solenoid
Incorrect PROM (on GM cars)
Catalytic Converter Sensor
EGR flow sensor
Coolant temperature sensor
Crankshaft position sensor
Engine RPM sensor
Electronic spark controls
Idle speed control (ISC)
Air temperature sensor
Air conditioning sensor (switch)
Turbo boost limiting system (waste gage)
Torque converter clutch
Road Speed sensor
Oil and temperature sending
*The failure of some of these sensors can result in abnormal combustion temperatures and pressures, blown head gaskets, burnt pistons, piston scuffing and burnt valves, bearing failure and lack of power and may result in eventual engine failure.
- Replace distributor, wiring, coil and spark plugs to avoid poor performance. On V-8's check plug routing.
- Final road test vehicle, do not return to customer unless you consider vehicle operating according to OE specification.
- Give customer printout of exhaust gas analysis.
Caution: This partial list of Recommended Installation Procedures and Instructions is intended only as a guide. If you are not qualified to perform an installation, do not attempt it, as you may be liable for the resulting engine failure. Other procedures may be necessary to ensure proper engine operation.
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